Common MOSFET process for plural devices

ABSTRACT

A core process is described for the manufacture of a Schottky, MOSFET or Accufet, using a plurality of identical manufacturing steps, including spaced trenches, in a single production line, with the device type to be produced being defined at an implant and diffusion stage for forming very low concentration mesas for a Schottky; higher concentration mesas with source regions for Accufet devices and a channel implant and source implant for a vertical conduction MOSFET.

RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 60/543,320, filed Feb. 9, 2004.

FIELD OF THE INVENTION

This invention relates to semiconductor devices and more specifically relates to a common or base process and fabrication equipment therefore which can be easily modified to produce a variety of different devices.

BACKGROUND OF THE INVENTION

Semiconductor fabrication lines and equipment and processes are commonly tailored for the manufacture of wafers with a given die structure. Thus different lines are dedicated to the manufacture of a single type device, for example, only a Schottky diode; or only an Accufet device (such as shown in U.S. Pat. No. 6,437,390) or only a vertical conductor trench type power MOSFET. Because the lines are dedicated to a particular product, the whole line will be closed when there is a reduced demand for that particular product, thus wasting a large capital investment.

Furthermore, the manufacture of semiconductor devices employs different mask patterns and process steps for the manufacture of different kinds of devices. Thus, different masks, tools and process directions are needed for the manufacture of different devices such as trench type MOSFETs, trench type Schottky diodes, and Accufet MOSFETs.

The different process steps and mask patterns require device specific manufacturing steps and masks, leading to added manufacturing complexity, inventory, operator training and the like.

It would be desirable to reduce the number of steps and masks needed to make diverse devices and to emphasize and exploit the commonality of such devices and their basic processes.

BRIEF DESCRIPTION OF THE INVENTION

In accordance with the invention, selected junction patterns and mask patterns in three diverse devices, e.g. trench MOSFETs; trench Schottkys and Accufet MOSFET devices are identified and employed as common manufacturing steps for each device to establish a basic common process prior to metallizing. The individual devices are made by selecting specific implants prior to the premetal point in the manufacturing process. Thus, multiple devices can be made by the same basic mask set on the same wafer.

Further in accordance with the present invention, a core process and the equipment therefore is arranged to be easily varied to produce a plurality of distinct products with minor process changes that do not require new line design or new line equipment. Accordingly, a device manufacturer would no longer need three dedicated lines with duplicated expensive equipment to be able to manufacture different and distinct products. Further, products with low demand, which might not otherwise warrant the cost of a dedicated product line can now be easily produced on a limited run basis when the single core line can be freed for the low demand product. By way of example, a common core process has been developed which will enable the manufacture of Schottkys, Accufet devices or trench MOSFETs using the same basic equipment of a single processing line.

The novel core process comprises the steps of:

-   -   1. Preparing a common wafer of a given concentration type.     -   2. Preparing the wafer surface.     -   3. Passing through an ion implant and diffusion stage, which         will be adapted to the particular part to be made and         epitaxially depositing a junction-receiving layer on the         substrate.     -   4. Go through appropriate cleans and masking and etching         parallel (or cellular) trenches into the epi layer and through         whatever implant layers were formed in step 3.     -   5. Forming a gate oxide on the walls of the trenches.     -   6. Depositing a conductive polysilicon layer over the wafer top         to fill the trenches.     -   7. Etching away the polysilicon over the mesas formed by the         trenches and into the trenches themselves.     -   8. Depositing an interlayer oxide over the top of the         polysilicon trench inserts.     -   9. Depositing a conductive silicide over the mesa tops.     -   10. Applying top and bottom contacts.

There are obviously related cleans and other acid treatments which are common to the above basic steps.

It now becomes possible, by the use of different implants at step 3 to define a Schottky, or an Accufet device, or a vertical conduction trench MOSFET without a change of any of the other core steps, thus permitting the use of a single line to manufacture any one of 3 distinct devices.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the basic common junction patterns to be employed for the manufacture of any one of three different products which are differentiated only by selection of different implants before metallizing.

FIG. 2 shows the device of FIG. 1 configured, before metallizing, to be a trench Schottky device.

FIG. 3 shows the device of FIG. 1 configured, before metallizing, to be an Accufet MOSFET device.

FIG. 4 shows the device of FIG. 1 configured, before metallizing, to be a trench MOSFET device.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the basic common elements of three different devices (of FIGS. 2, 3 and 4) after metallizing. The same basic wafer, mask set and process is used for all devices.

The common device properties are shown for a cross-section of two of a plurality of spaced cells in a silicon wafer 20. Wafer 20 has an N⁺ body 21 having an N type junction-receiving epitaxial layer 22 thereon. The thickness and concentration of layer 22 are determined by the desired reverse voltage rating for the devices.

A plurality of spaced trenches 30, 31 are formed and lined with gate oxide 32, 33 respectively. The trenches are then filled with polysilicon masses 34, 35 respectively (which will be implanted to be N⁺ or P⁺, depending on the device to be made). A cap oxide 36, 37 respectively is then added and etched. A TiSi₂ layer is formed on the top of the mesas as shown.

Different implants are employed before the TiSi layer step as will be described for FIGS. 2, 3 and 4, and a source metal 40 and at drain metal 41 are later added.

If the device is to be a trench Schottky (as shown in co-pending application (IR-1663), Ser. No. 10/193,783 entitled TRENCH SCHOTTKY BARRIER DIODE in the names of Kohji Andoh and Davide Chiola), and as shown in FIG. 2, an N⁻ region 60 is formed by implantation before the TiSiO₂ and metallizing step.

If the device to be formed is an Accufet MOSFET device, of the kind shown in U.S. Pat. No. 6,437,390, an N⁻-region 70 and an N⁺ source 71 are formed before the TiSi₂ steps and metallizing.

If the device is to be a trench MOSFET, a P⁻ channel region 80, a P⁺ contact region 81 and an N⁺ source region are added by implanting before the TiSi₂ and metallizing steps.

Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims. 

1. A core process sequence having manufacturing steps common to a plurality of distinct devices which are respectively produced by the addition of a common implant and diffusion stage; said process sequence comprising, in combination, a wafer supply of wafers having a high concentration of impurities of one of the conductivity types and having an epitaxially deposited layer of a lower concentration of said one of said concentration types; an implant and diffusion stage for selectively implanting and diffusing an impurity of either of the conductivity types into the top of said epitaxially deposited layer; a trench stage for forming spaced trenches into the tops of said wafers and through the depth of said impurity of either of said concentration types; a first insulation stage for growing a first layer of insulation on the walls and bottom of said trenches; a conductive polysilicon deposition stage for growing a conductive polysilicon mass to fill said trenches; an interlayer oxide forming stage for depositing an interlayer oxide atop said polysilicon masses; a silicide deposition apparatus for depositing a conductive silicide atop the mesas formed between said trenches; and a metalization apparatus for depositing conductive top and bottom metal electrodes on the top and bottom surfaces of said wafers; said implant and diffusion stage defining the production of one of a Schottky diode, Accufet device, or vertical conduction trench-type MOSFET by the selection of a concentration type and implant dose and diffusion drive.
 2. The core process sequence of claim 1, wherein the selection of a low dose implant of the same concentration as said epitaxial layer is followed by a high dose implant to form source regions in said low dose implant.
 3. The core process sequence of claim 1, wherein the selection of a first low dose implant of the same concentration of said epitaxial layer and the subsequent selection of a further lower dose implant following said low dose implant defines a Schottky diode.
 4. The core process sequence of claim 1, wherein the selection of a low dose implant of the opposite conductivity type to that of said epitaxial layer forms a channel region; and subsequent implant of a high dose of the same concentration as the epitaxial layer defines a vertical conduction trench type MOSFET.
 5. The process of manufacture of one of two or more distinct semiconductor devices in a process having a plurality of identical process steps; said identical process steps comprising the sequence of: a) providing a wafer having a junction-receiving surface of one of the conductivity types; b) forming a plurality of identical spaced trenches into the junction receiving surface of said wafer; c) forming an insulation layer over the walls and bottom of each of said trenches; d) filling each of said trenches with a conductive polysilicon; e) insulating each of the polysilicon masses in each of said trenches by an interlayer oxide; f) forming a conductive silicide on the tops of the mesas between spaced trenches; g) forming top and bottom contacts on the top and bottom surfaces of said wafer; and h) after step (a) and before step (b), implanting and diffusing at least one blanket diffusion which, after subsequent processing, defines two or more distinct device types.
 6. The process of claim 5, in which said two or more distinct device types include a vertical conductive trench type MOSFET and a Schottky diode.
 7. The process of claim 6, which further includes as a distinct type device, an Accufet device. 